2. Kanban : Pull System
2
Basic Principle
of
KANBAN
Updated: June 2nd, 2006
3. Kanban : Pull System
3
Controls production of the
right parts, in the quantities, at
the right moment, in every
stage of production.
Updated: June 2nd, 2006
4. Kanban : Pull System
4
An instruction for:
withdrawing products from the
preceding process
Producing the quantity that has
been withdrawn
Updated: June 2nd, 2006
5. Kanban : Pull System
5
Two types of Kanban
the Production Instruction Kanban
(PIK)
the Withdrawal Kanban (WK)
Updated: June 2nd, 2006
6. KANBAN CARD
6
DEFINITION:
kanban card = communication tool
TARGETS:
Indicate the part number / part name and
the quantity to be produced per card
Information on the card
- name of the supplier and name of the customer.
- point of storage (shopstock) and point of use
Updated: June 2nd, 2006
7. Kanban : Pull System
7
From internal
customer
Batch Building Box
WK
PIK
Assembly
line a a a
a A A A
b
c WK WK WK To internal
b b
b customer
B B
c c
C C
Supermarket /
shopstock
Production instruction Kanban Withdrawal Kanban loop
loop
Updated: June 2nd, 2006
8. Instruction Kanban (PIK)
8
1. Production batch = 1 Kanban (no changeover) The production order for
the reference. A 1 Kanban corresponds to 1 box to produce
2. Production batch = n Kanbans (changeover time) Kanban with batch-
building box
Updated: June 2nd, 2006
9. Instruction Kanban (PIK)
9
When different references are manufactured in the same process with
changeover time, the production order is a pack of Kanban (a
batch).The production order is not given until the batch has been
constituted .
A batch of n Kanbans corresponds to n packaging units to produce.
Example: The batch of five Production Instruction Kanbans is the
production order.
Updated: June 2nd, 2006
10. Withdrawal Kanban
10
The order for withdrawing the
reference. It is used between
sequencer and production line
processes within a site to
instruct the internal supply team
to pick up the parts from
upstream.
Updated: June 2nd, 2006
11. Withdrawal Kanban
11
The downstream process at the end of the
line
The sequencer at the end of the line
Circulation of this Kanban must follow two
principles:
Simultaneous transfer of the parts and the
corresponding information (the Kanban is
attached to the packaging unit or part)
Frequent transfer (several times per shift – if
Updated: June 2nd, 2006
13. Batch Building Box
13
DEFINITION:
Is a box accumulating the kanban cards in
order to build the batch
The batch size reflect the flexibility of the
production line / machine
(Faurecia proposes to invest 10% of the production time in tool change)
The batch building box is placed at the end of
the line
TARGET:
build a production batch with a fixed June 2 , 2006
Updated: size nd
14. END OF LINE STOCK
14
DEFINITION:
reflect the flexibility and reliability of the
machine / production line.
This stock:
*is designed to contain all product variants (or at least the most
demanded)
*is located at the end of the machine / production line.
TARGETS:
allow the customer to pick the parts he needs
without waiting the parts to be produced
Updated: June 2nd, 2006
15. WAITING QUEUE
15
The practical way of maintaining the
withdrawal order of the packaging units.
It represents the manufacturing
sequence of the production line and
uses gravity to feed the cards.
Updated: June 2nd, 2006
16. WAITING QUEUE
16
DEFINITION:
WQ helps to accumulate the batches
respecting the FIFO
The waiting queue is placed at the
beginning of the production line
TARGET:
give to the production a clear sequence
nd
Updated: June 2 , 2006
to be respected for the production of the
17. 6 Rules for Effectiveness
17
No bad part may reach next process
The number of parts in each packaging unit
must be identical to the number of parts
noted on the kanban
The downstream process must withdrawal
according to the kanban the exact quantity of
the right product at the right time
Updated: June 2nd, 2006
18. 6 Rules for Effectiveness
18
The output of the upstream process must
match the quantity withdrawn by the
downstream process
The number of Kanbans must been reduced.
The number of PIK reflects the stock
levels. It is essential to lower the kanban
as progress is achieved.
The Kanbans must be used to adapt to
fluctuations in demand
Updated: June 2nd, 2006
19. ADVANTAGES
19
• Respect the customer demand
• Produce at the rythm of the customer (Takt
Time)
• Visualisation of the production management
• Regular and controlled production
• Improve the reactivity
Updated: June 2nd, 2006
20. Kanban : Pull System
20
• Video
“Palmela Fixed Batch Kanban”
• Kanban Pull Systen Model – Simulation
• Shopfloor visit: waiting queue, batch building
box, kanban
Updated: June 2nd, 2006
23. Definition – Standardized Work
A timed description of the best possible
succession of basic manual tasks for an
operator.
It includes:
- transformation and control operations
- but also movements
- other necessary steps included in the cycle
time.
24. Objective
Achievement of safety, quality, productivity and delivery
performance objectives through:
• reduce dangerous movements
• apply controls and ability to repeat
• correct use of machines
• identification and elimination of the 7 wastes
• training and evaluation of the operators
25. Key Factors
•Allows the repeatability of the sequence of basic tasks during
each cycle with low variability of the process.
•Work content may differ according to product options
• Separate the man and machine
• Reduce frequencial operations (reduce variability)
• Quick and efficient treatment process of improvement ideas
through the operator
26. Cycle Time and Takt Time
Takt time is a rate that represents, in
seconds, the number of parts the
customer expect us to deliver
Cycle time is a rate, in seconds, at which
the product must be produced in order to
offset “waste” in the system and achieve
the Takt Time needed to satisfy the
customer
27. Work Content
Sum of the basic tasks carried out at each workstation to obtain
a complete and good product (amount of work for a part)
It is measured by timing the cycle of each operator using a cycle
time measurement form.
The measurement must be based on 20 consecutive cycle times
(everything included).
Time necessary for self-inspection has to be included.
For each operator, we will show the minimum time, wait time
excluded, as well as the maximun and mean time.
28. FORMS
The standardized work goal is based on 3
forms:
• Standardized Work Chart ( #)
• Work Combination Table (#)
• Standard Operation Sheet (#)
29. Standardized Work Chart
- describes the succession of basic tasks
and the position of the operator for each of
them.
- helps to visualize easily the operator
movements and to identify useless
movements
- determines the number of parts between
each workstation.
30. Standardized Work Chart
Standardized work chart FAU-F-PS-5006 /1
Operation from: Date:
Product: panel Process: welding, assembly
to:
Takt Time Expected nb
Sketch operator's w orkstations. Part aw aiting operator parts waiting
Break his/her w ork dow n into (e.g. At end of cycle)
elem entary tasks corresponding
to those in the standard w ork Machine 4 (Welding) Quality
com binaison table. inspection
61 s Special hasard or
Add sym bols Safety
safety action
Station 5 (Inspection)
Cycle time Movement
with part
without part
Production
FP cart
51 s 5 nam e:
2 1
6
Expected 3 date:
number of
parts waiting 7
10 4
8
Methods
name:
9
3
Num ber the
operator's position date:
for each job
Quality
name:
date:
31. Work Combination Chart
- gathers all the basic identified tasks on the
Standardized Work Chart and details each
specific time.
- helps differentiate times walking and
waiting from working on the workstation.
- allows to evaluate the difference between
cycle time and takt time and to verify that
operators do not wait for the machine.
33. Standard Operation Sheet
- details all the instructions to realize an
operation at a workstation describing it by
the safest, easiest and most efficient way.
- contrary to the standardized work chart
and work combination table relative to an
operator, this document is linked to a
process or a basic operation from the
process.
34. Standard Operation Sheet
Important Safety issue: to be used if a real risk Whole Time neede
remarks can exists for employees ! Standardized Com
be written in STANDARD OPERATION FA U-F-PS-241 / EN
version 02
Plant :
Washington
Document N o.:
Rev ision Lev el:
xxxx
4
bold or Part
Number xxx Part Name Bolster Line : EQ Bolster
Work-
station: Woodstock
Page
No: 1/1
underlined No. Operation = SAFETY = QUALITY = TIP
Time:
30 Sec Sketches / Photo's / etc.
4
1
Remove cavities 3 & 4 from the mould tool.
Remove parts from tool Place parts onto left side of bench (Fig1)
Spiking frame
big font Remove the spiking Remove the waste then place the frame onto the bench
Cavities
enables 2 frame from the upper
Ensure frame handle is pointing away from you and spikes are pointing upwards. 1
4 Cavities 1
3 2 2
tool
Fig 1.
operator to 3
read from Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to push
3 onto to stand.
the existing
waste into the granulator (fig 2).
worstation
Self-Quality check Granulator
Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the
Cooling stand
upper mould tool (fig 1)
4 frame from the
"Alt+Enter" underneath bench Ensure that the handle is pointing towards you is fully located against the censor
Fig 2.
White 5
to go on the
- Take one white & green LH clip from the dispenser.
next line in 5
Place one white & green - Place the green clip into the center clip position and the white into the bottom location on
cavity 4.
clip into cavities 3&4 - Take one white & green RH clip from the dispencer.
the same - Place the green clip into the center cl Green
White
cell Issued Signat ure/ Dat e
Checked Signat ure/ Dat e
Approved Signat ure/ Dat e
SKILLED Signat ure/ Dat e
Fig 3.
N on C onforming Product:
Name: Name: Name: OPERAT OR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito r
Function: Function: Function: Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader.
Tip : put the
stress on Operator who participated Non-Comformancies
special in setting up the Standard Reaction rules have to
comments Operation be adapted to the
workstation
35. Standard Operation Sheet
Document No.: xxxx
STANDARD OPERATION FAU-F-PS-241 / EN
version 02
Plant :
Washington Rev ision Lev el: 4
Part Work- Page
Number xxx Part Name Bolster Line : EQ Bolster station: Woodstock No: 1/1
Time:
No. Operation = SAFETY = QUALITY = TIP
30 Sec
Sketches / Photo's / etc.
Remove cavities 3 & 4 from the mould tool. 4
1 Remove parts from tool Place parts onto left side of bench (Fig1)
Spiking frame
Remove the spiking Remove the waste then place the frame onto the bench
Cavities
2 frame from the upper
Ensure frame handle is pointing away from you and spikes are pointing upwards. 1
4 Cavities 1
3 2 2
tool
Fig 1.
3
Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to push
3 onto to stand.
the existing
waste into the granulator (fig 2).
Granulator
Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the
Cooling stand
upper mould tool (fig 1)
4 frame from the
underneath bench Ensure that the handle is pointing towards you is fully located against the censor
Fig 2.
White 5
- Take one white & green LH clip from the dispenser.
Place one white & green - Place the green clip into the center clip position and the white into the bottom location on
5 clip into cavities 3&4
cavity 4.
- Take one white & green RH clip from the dispencer.
- Place the green clip into the center cl Green
White
Fig 3.
Issued Signat ure/ Dat e
Checked Signat ure/ Dat e
Approved Signat ure/ Dat e
SKILLED Signat ure/ Dat e
Non Conforming Product:
Name: Name: Name: OPERATOR P lace rejects in reject co ntainer. Reco rd o n P ro cess M o nito r
Function: Function: Function: Name: Sheet. If 3 o r mo re rejects fo und with same fault call Gap Leader.
